US2973321A - Process of making an improved carboxylic acid salt complex thickened lubricant - Google Patents

Process of making an improved carboxylic acid salt complex thickened lubricant Download PDF

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US2973321A
US2973321A US634450A US63445057A US2973321A US 2973321 A US2973321 A US 2973321A US 634450 A US634450 A US 634450A US 63445057 A US63445057 A US 63445057A US 2973321 A US2973321 A US 2973321A
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range
composition
acid
molecular weight
viscosity
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US634450A
Inventor
Arnold J Morway
Clyce R Daniels
Robert P Spray
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ExxonMobil Technology and Engineering Co
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Exxon Research and Engineering Co
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Priority to NL97276D priority Critical patent/NL97276C/xx
Priority to NL257238D priority patent/NL257238A/xx
Priority to NL109104D priority patent/NL109104C/xx
Priority to NL205854D priority patent/NL205854A/xx
Priority to BE546615D priority patent/BE546615A/xx
Priority to NL224101D priority patent/NL224101A/xx
Priority to GB8289/56A priority patent/GB778651A/en
Priority to DEE12146A priority patent/DE1053124B/en
Priority to FR1152175D priority patent/FR1152175A/en
Application filed by Exxon Research and Engineering Co filed Critical Exxon Research and Engineering Co
Priority to US634450A priority patent/US2973321A/en
Priority to GB434/58A priority patent/GB824526A/en
Priority to DEE15228A priority patent/DE1087736B/en
Priority to FR755962A priority patent/FR73068E/en
Priority claimed from US849432A external-priority patent/US3018249A/en
Priority to GB34433/60A priority patent/GB913579A/en
Priority to FR842411A priority patent/FR78613E/en
Application granted granted Critical
Publication of US2973321A publication Critical patent/US2973321A/en
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    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M129/00—Lubricating compositions characterised by the additive being an organic non-macromolecular compound containing oxygen
    • C10M129/02—Lubricating compositions characterised by the additive being an organic non-macromolecular compound containing oxygen having a carbon chain of less than 30 atoms
    • C10M129/26—Carboxylic acids; Salts thereof
    • C10M129/28—Carboxylic acids; Salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C51/00—Preparation of carboxylic acids or their salts, halides or anhydrides
    • C07C51/41—Preparation of salts of carboxylic acids
    • C07C51/412—Preparation of salts of carboxylic acids by conversion of the acids, their salts, esters or anhydrides with the same carboxylic acid part
    • C—CHEMISTRY; METALLURGY
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    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L1/00—Liquid carbonaceous fuels
    • C10L1/10—Liquid carbonaceous fuels containing additives
    • C10L1/14—Organic compounds
    • C10L1/18—Organic compounds containing oxygen
    • C10L1/188—Carboxylic acids; metal salts thereof
    • C10L1/1881—Carboxylic acids; metal salts thereof carboxylic group attached to an aliphatic carbon atom
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    • C10M117/02—Lubricating compositions characterised by the thickener being a non-macromolecular carboxylic acid or salt thereof having only one carboxyl group bound to an acyclic carbon atom, cycloaliphatic carbon atom or hydrogen
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    • C10M129/26—Carboxylic acids; Salts thereof
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    • C10M129/30—Carboxylic acids; Salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having 7 or less carbon atoms
    • C10M129/32—Carboxylic acids; Salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having 7 or less carbon atoms monocarboxylic
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    • C10M129/40—Carboxylic acids; Salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having 8 or more carbon atoms monocarboxylic
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    • C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
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    • C10N2040/00—Specified use or application for which the lubricating composition is intended
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    • C10N2040/24—Metal working without essential removal of material, e.g. forming, gorging, drawing, pressing, stamping, rolling or extruding; Punching metal
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    • C10N2040/255—Gasoline engines
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    • C10N2070/02—Concentrating of additives

Definitions

  • the present invention is concerned with a process for preparing a fluid lubricating composition thickened with the metal salts of acetic acid and intermediate molecular weight monocarboxylic acids.
  • this invention proposes an improvement of a process wherein a fluid lubricating composition is formed at a temperature in the range of 250 to 340 F., by dispersing in a lubricating oil having an initial viscosity in the range of 55 to 100 SSU at 210 F. and a viscosity index in the range of 40 to 100, the metal salts of an acetic acid and of an intermediate molecular weight monocarboxylic acid having from 7 to 12 carbon atoms, the molecular ratio of acetic acid to intermediate molecular weight acid being-in the range of :1 to 25:1.
  • the improvement of this invention comprises maintaining the weight percentage of the metal salts in the composition in the range of 20 to 50, homogenizing or shearing the composition at a temperature in the range of 80 to 150 F., at ashearing force in the range of 100,000 to about 500,000 or more reciprocal seconds, sufficient to assure that the composition has a good storage stability as indicated by no tendency to separate solids when stored at 100 F. for at least 40 days.
  • the homogenized composition is then diluted with further amounts of the lubrieating oil until the weight percentage of the metal salts in the composition is in the range of 4 to 10, and further homogenized at a temperature in the range of 80 to 150 F.
  • the fluid lubricating composition of this invention is particularly useful as a marine diesel cylinder lubricant. It gives trouble-free operation and results in extremely low wear. It also satisfactorily answers the problem of lubricator life that is associated with-marine diesel engines.
  • the lubrication to a marine diesel is'metered through a lubricator that has a sight-glass filled with a mixture of glycerine and water. The oil is passed dropwise through the sight-glass. Most oils of this type result in rapid clouding or displacement of the sight-glass fluid with the oil being metered, whereas the oil of the present invention has a Manzel lubricator life of over 40 days.
  • the lubricating oil which is thickened can be generally of any type known to the prior art, having a viscosity of about 60 to 10,000 SSU at 100 F. and about 55 to 100 SSU at 210 F. It is preferred that the lubricating oil have an initial pour point of about +20 to F., and a flash point of about 350 to 650 F. Best results are obtained with a lubricating oil having an initial viscosity index in the range of 40 to 100. Synthetic as well as mineral lubricating oils can be employed as part or all of the liquid phase of the lubricating composition.
  • oils include synthetic lubricating oils of the hydrocarbon, hydrocarbon polymer, ester, complex ester, formal, mercaptal, polyalkene oxide, silicone and similar types. Synthetic oils such as the di-2-ethylhexyl sebacate, di-C 0x0 azelate, di-c -oxo azelate or complex esters of glycols, dicarboxylic acids and alcohols or monocarboxylic acids can be used.
  • the low molecular weight monocarboxylic acid used is acetic.
  • the intermediate molecular acids used have from 7 to 12 carbon atoms per molecule.
  • the mixtures used preferablyaverage'about 10 carbon atoms per molecule.
  • Either saturated or unsaturated fatty-acids may be utilized althoughjthe saturated acids are preferred.
  • Straight chain or substantially straight chain configuration isalsopreferred.
  • the average saponification value of the single or mixed intermediate molecular weight acids is preferably in the range of 310 to 440, more preferably 320 to 380.
  • Examples of such acids are 5-methyl-2-hexanoic,.heptanoic, octanoic, nonanoic, decanoic.- Commercial mixtures of these intermediate molecular weight carboxylic acids having an average saponification number of about 320 to 380 are particularly preferred.
  • the Oxo acids pretained and in concentrations above this, sedimentation or solidification becomes a problem.
  • the metals used in forming the salts are preferably valkaline earth metals such as calcium, strontium, magnesium or barium, calcium being particularly preferred.
  • vinvention is concerned with the improvement of .the organic metal salt-oil blend after it has been formed.
  • v"'Ihis.. .vil-metal salt mixture can be formed in any convenient manner.
  • the mixed acids may be co-neutralized in situ in the oil if desired. This is particularly desirable in cases in which the salts have the same metal constituent.
  • the mixture of metal salts can also be prepared by separately preforming the salts in aqueous media and then dehydrating. They also can be formed separately in volatile solvents with removal of the solvent'before the metal salts are added to the lurbicating oil. It is important that the final composition arrived at be substam tially anhydrous. This is done by cooking the oil containing the metal salts at a temperature in the range of 250 F. to 350 F. until the water content is below 0.5 wt. percent.
  • a particularly preferred method of manufiacturingthe starting material used in this invention, when using lime to form the salts, is to add the lime in two portions.
  • Commercial hydrated lime can contain up to of calcium carbonate which is not too reactive and generally causes excess alkalinity in the final product. This carbonate forms sediment in sight-glasses and in some manner imparts greater viscosity to the finished lubricant.
  • the acids are taken up by reaction with the hydrated lime.
  • the excess acid particularly the acetic acid
  • the calcium carbonate By employing a slight (24%) deficiency in the amount of lime first added, the excess acid, particularly the acetic acid, will then react with the calcium carbonate and remove it. The small amountof remaining excess acid is then new tralized with a second addition of hydrated lime.
  • the second addition of lime can be made after the initial saponification is complete and the mixture is hot (200-225 F.), and preferably after a determination of. free acidity has been "made. It is desirable to adjust the free alkalinity at this point because higher temperatures would volatilize the free acetic acid. Also it is desirable that the second addition of lime be willcient to make the lubricant slightly alkaline.
  • the oil so obtained containing the metal salts in an amount in the range of 20 to 50 wt. percent is then treated according to the method of this invention.
  • the intermediate molecular weight acid was a commercially available acid having approximately the following composition:
  • the phenyl alpha naphthylamine was then added, the mixture was cooled by passing cold water to the kettle jacket, and diluted with 1200 gallons of the lubricating oil. The mixture was cooled to 150 F. and formed a semi-solid grease. This grease was then pumped by line 8 through a homogenization zone 9 comprising a model G-1'25 Charlotte mill set at 0.004 inch clearance. The homogenized mixture was then transferred by line 10 to a 36,000 lb. storage tank '11. The sulfated ash and free alkali of the base at this time were: Sulfated ash, 15.82 wt. percent and free alkali as NaOH, 0.50 wt. percent.
  • the grease was passed by line 12 to a homogenization zone 13 comprising a model G-125 Charlotte mill set at 0.004 inch clearance. After this homogenization, the material was passed by line 14 to a 70,000 lbs. storage tank 15 equipped with a side entrance mixer. In this tank the homogenized material was diluted to the desired soap content, with additional lubricating oil supplied from zone 17 via line '18 as measured by a sulfated 'asli (CaSO of 5.5 to 5.8%. After addition of 6,210 additional gallons of the lubricating oil, the sulfated ash was 5.5 wt. percent, and the material had a viscosity of 1766 SSU at 100 F. and 132 SSU at 210 F.
  • Tlie screen test comprises fitting a four-inch, 40.-r'nesh screen (of -any suitable material) to a Biichner tunnel.
  • Afterfiltering of the sample is com- 'and then is wiped-off on' the bottom andreweighed. ilhe "screen-is --examinedfor lumps, jelly, crystals and dirt.
  • Weights in excess of about 0.5 gram indicate the presence-:of jellyand possiblywater.
  • Water content is determined by ASTM D-95-46, Method of Test for Water in Petroleum Products and Other Bituminous Materials.
  • the viscosities are determined according to ASTM D-44546 using Ubbelohde viscosity tubes, size No. 3.0 for the 100 F. determination and size No. 0.3 for the 210 F. determination. With one filling of the viscosity tube, four successive determinations are made, the first one-being discarded becausethe lubricant is non-Newtonian. The average of the last 'three runs is the viscosity used.
  • the four ball .wear test scar spot indicates the excellent anti-wear resistance of the lubricant of this in vention. Friction and wear is determined in this test by the precision-shell four ball wear tester described in a United States Steel Lubricants Testing Laboratory, National Tube Division, Report, November 1, 1952. The conditions are:
  • homogenization is intended to include any method of subjecting the lubricant to shearing forces. Besides the colloidal mill (Charlotte mill) identified, this milling can be carried out using the Gaulin homogenizer made by Manton-Gaulin Company, the Morehouse mill made by Morehouse Industries, or any device capable of f imparting rates of shear approaching 100,000 to 750,000 reciprocal seconds or more.
  • the homogenization of the concentrated (20-50 wt. percent salts) metal salt composition should be carried out to an extent sufficient so that there is no particle size above 500 microns, and the average particle size is 300 microns under microscopic scanning.
  • the second homogenization is carried out to an extent sufficient so that the material will pass the centrifuge test above described and completely pass through the 0.008 inch filter spacings. While the temperature of homogenization does not appear to be critical, it is desirably in the range of 80 to 150 F. in order to obtain best results. v
  • Thedeaeration step is greatly desired because a lubricant, when employed as an upper cylinder lubricant in marine diesel engines, is passed through a'lubricator (e.g., a Manzell lubricator) that acts as a displacement pump. Any air entrained in the lubricant can cause vapor lock in-the dispensing pump or lines.
  • a'lubricator e.g., a Manzell lubricator
  • Any air entrained in the lubricant can cause vapor lock in-the dispensing pump or lines.
  • Prior art preparations give relatively short lub ricator lives. However, the product of thisinvention has more than tripled lubricator life.
  • EXAMPLE II The following data show that it is important that the final product contain at least about 4 .wt. percent of the complex metal salts. Greases were prepared in a manner similar to that described above, having various metal salt contents, and were tested according to the four-ball wear test described .above. The scar spot diameters obtained vs. the percent sulfated ash in the lubricant are given in the following Table II.
  • compositions were made up as follows: A steam jacketed fully scraped kettle was charged with 5980 lbs. of a lubricating oil and 1480 lbs. of lime. These were mixed to form a smooth slurry. To the slurry was added a blend of 480 lbs. of the intermediate molecular weight acid and 2000 lbs. of acetic acid at a rateof 34 lbs. per minute. This addition was done through atop opening in the kettle while .the paddles were rotating at 17 r.p.m. After addition of the acid, the temperature-rose to 205 F. Stirring was continued for 30 minutes with the paddles at 34 r.p.m. Steam was then passed into the kettle jacket and-the temperature raised to 320 F.
  • the heating was then discontinued and cooling water was passed through the kettle jacket. During this cooling, 10,500 lbs. of additional lubricating oil were added. The phenyl alpha naphthylamine was added and the grease at a temperature of 239 F. was-left to cool overnight. The paddle and the cooling water were shut oft.
  • the lubricating composition of this invention is particularly directed to this problem of lubricating marine diesel engines.
  • This composition differs somewhat from the conventional mineral oil distillates previously used in that it is a fluid grease and resembles most greases in appearance, although it still is free-flowing.
  • the major function of a diesel cylinder lubricant is to reduce friction and wear of the piston rings and liner surfaces. This is done by injecting the: lubricant into each cylinder and it is, in a large measure, consumed during fuel combustion.
  • the increased liner wear experienced with residual fuels is believed to be mainly due to corrosion which results from the high sulfur content of residual fuel and the abrasive action of the prodnets of incomplete combustion of the heavy fuel components.
  • Residual fuels usually range in sulfur content from 2 to 4%, while distillates generally fall under 1.5%.
  • Composition A of Example 3 was tested in a residual fuel burningmotor ship Esso Little Rock, an 18,000 ton tanker powered by a five cylinder 75,000 H.P., two.- cycle, single-acting, opposed piston, Sun-Doxford engine. For purposes of comparison, a high quality', premium control oil was used. This was a deasphalted, phenol treated and solvent extracted residuum from a blend of parafiinic crudes having a viscosity of 85 SSU at 210 F. and a viscosity index of 101.
  • a substantially anhydrous fluid lubricating composition is formed at a temperature in the range of 250 to 340 F. by dispersing in a mineral lubricating oil having an initial viscosity in the range of to' SSUat 210 F. and a viscosity index in the range of 40 to 100, the metal salts of acetic acid and ,of an intermediate molecular weight monocarboxylic acid having from 7 to 12 carbon atoms, the molecular ratiol of low molecular weight acid to intermediate molecular: Weight acid being in the range Iof"10:l to 25:1, .the improvement which comprises maintaining the wt. per?
  • cent of said metal salts in said composition in the range of 20 to 50, homogenizing the composition at least twice at a temperature in the range of 80 to F. and at a shearing force in the range of 100,000 to 500,000 reciprocal seconds, diluting the composition so homogenized with further amounts 'of said'lubricating oil until 'the weight percentage of said metal salts is in the range of- 4 to 10 and then further homogenizing the diluted com? position at a shearing force in the range of 100,000 to 750,000 reciprocal seconds and a temperature in .the range of 80 to 150 F. to obtain a fluid product .ofi improved stability having a viscosity in the range of 80 to 200 SSU at 210 F.
  • a process which comprises forming at a temperature in the range of 250 to 340 F., a substantially anhydrous mixture of 20 to 50 wt. percent of the calcium metal salts of acetic acid and a monocarboxylic acid having from 7 to 12 carbon atoms in a liquid lubricating oil, the ratio of acetic to said monocarboxylic acid being in the range of 10:1 to 25:1, subjecting said mixture to shearing at least twice at a temperature in the range of 80 to 150 F. and at a shearing force in the range of 100,000 to 500,00 reciprocal seconds, diluting the mixture with additional lubricating oil to a metal salt content in the range of 4 to 10 wt. percent, and then further shearing the diluted mixture at .a temperature in the range of 80 to 150 F. and a shearing force it; the range of 100,000 to 750,000 reciprocal seconds to obtain an improved fluid lubricating composition.

Description

Feb. 28, 1961 on- 2,973,321
PROCESS OF MAKING AN IMPROVED CARBOXYLIC ACID SALT COMPLEX THICKENED LUBRICANT Filed Jan. 16, 1957 HOMOGENIZATION STORAGE HOMOGENIZATION & '4'
(I5 (I? DILUTION LURICATING 01L HOMOGENIZATION STORAGE 24 DEAERATING 1 F ILTERING Arnold J. Morway Cloyce R. Daniels Inventors Robert P. Spray By Zi M Attorney ture.
United States Fatent O PROCESS OF MAKING AN IMPROVED CARBOX- YLIC ACID SALT COMPLEX THICKENED LU- BRICANT Arnold J. Morway, Clark, N.'J., and Cloyce R. Daniels,
Bridgeville, and Robert P. Spray, Pittsburgh, Pa., assignors to Esso Research andvEngineering Company, a corporation of Delaware Filed Jan. 16, 1957, Ser. No. 634,450 3 Claims. (Cl. 252-39) The present invention is concerned with a process for preparing a fluid lubricating composition thickened with the metal salts of acetic acid and intermediate molecular weight monocarboxylic acids.
In brief compass, this invention proposes an improvement of a process wherein a fluid lubricating composition is formed at a temperature in the range of 250 to 340 F., by dispersing in a lubricating oil having an initial viscosity in the range of 55 to 100 SSU at 210 F. and a viscosity index in the range of 40 to 100, the metal salts of an acetic acid and of an intermediate molecular weight monocarboxylic acid having from 7 to 12 carbon atoms, the molecular ratio of acetic acid to intermediate molecular weight acid being-in the range of :1 to 25:1.
The improvement of this invention comprises maintaining the weight percentage of the metal salts in the composition in the range of 20 to 50, homogenizing or shearing the composition at a temperature in the range of 80 to 150 F., at ashearing force in the range of 100,000 to about 500,000 or more reciprocal seconds, sufficient to assure that the composition has a good storage stability as indicated by no tendency to separate solids when stored at 100 F. for at least 40 days. The homogenized composition is then diluted with further amounts of the lubrieating oil until the weight percentage of the metal salts in the composition is in the range of 4 to 10, and further homogenized at a temperature in the range of 80 to 150 F. and a shearing force in the range of 100,000 to 750,000 or more reciprocal seconds, sufiicient to assure that the composition gives less than 5.0 wt. percentseparation of solids in the centrifuge test. In this manner there is obxtained a fluid product of improved stability. The resultant product is non-Newtonian and viscosity per se'is not a true measure of its consistency, but it has an approxi-' acid has usually been in the range of 2:1 and 25:1; The metalsalts are prepared by-well known means such as preforming, e.g., in a volatile solvent; by neutralization of theacids with metal bases such as calciurnhydroxide. .Such thickened oils are desirably anhydrous.
The fluid lubricating compositions preparedfrorn such metal salt complexes, however, have not beenas stable as desired, particularly when the ratio of the low molecular weight acid to the intermediate molecular weight acid the fluid composition and this is highly undesirable.
It has now been discovered that a very stable fluid composition, thickened with such metal salt complexes, can
concentrated metal salt solution followed by dilution, and then further homogenization to arrive at a stable strucis greater than 10: 1. The thickener tends tosettle out of This method of dual homogenization, i.e., lionr'ogeniza-g tion at high metal salt content-dilution-homogenization at low metal salt content, appears to be unique to this type of thickener as equivalent results are not obtained with other conventional types of thickeners known to the prior art, such as conventional fatty acid soaps, complex soaps formed from low molecular weight (C -C salts/high molecular weight (C -C soaps, etc.
The fluid lubricating composition of this invention is particularly useful as a marine diesel cylinder lubricant. It gives trouble-free operation and results in extremely low wear. It also satisfactorily answers the problem of lubricator life that is associated with-marine diesel engines. The lubrication to a marine diesel is'metered through a lubricator that has a sight-glass filled with a mixture of glycerine and water. The oil is passed dropwise through the sight-glass. Most oils of this type result in rapid clouding or displacement of the sight-glass fluid with the oil being metered, whereas the oil of the present invention has a Manzel lubricator life of over 40 days.
The following description of this invention with reference to the attached flow sheet, which forms a part of this specification, will serve to make the invention clear. The lubricating oil which is thickened can be generally of any type known to the prior art, having a viscosity of about 60 to 10,000 SSU at 100 F. and about 55 to 100 SSU at 210 F. It is preferred that the lubricating oil have an initial pour point of about +20 to F., and a flash point of about 350 to 650 F. Best results are obtained with a lubricating oil having an initial viscosity index in the range of 40 to 100. Synthetic as well as mineral lubricating oils can be employed as part or all of the liquid phase of the lubricating composition. They include synthetic lubricating oils of the hydrocarbon, hydrocarbon polymer, ester, complex ester, formal, mercaptal, polyalkene oxide, silicone and similar types. Synthetic oils such as the di-2-ethylhexyl sebacate, di-C 0x0 azelate, di-c -oxo azelate or complex esters of glycols, dicarboxylic acids and alcohols or monocarboxylic acids can be used.
The low molecular weight monocarboxylic acid used is acetic. The intermediate molecular acids used have from 7 to 12 carbon atoms per molecule. The mixtures used preferablyaverage'about 10 carbon atoms per molecule. Either saturated or unsaturated fatty-acids may be utilized althoughjthe saturated acids are preferred. Straight chain or substantially straight chain configuration isalsopreferred. The average saponification value of the single or mixed intermediate molecular weight acids is preferably in the range of 310 to 440, more preferably 320 to 380.
Examples of such acids are 5-methyl-2-hexanoic,.heptanoic, octanoic, nonanoic, decanoic.- Commercial mixtures of these intermediate molecular weight carboxylic acids having an average saponification number of about 320 to 380 are particularly preferred. The Oxo acids pretained and in concentrations above this, sedimentation or solidification becomes a problem.
The metals used in forming the salts are preferably valkaline earth metals such as calcium, strontium, magnesium or barium, calcium being particularly preferred.
.Other conventional grease-forming metals can be used.
vinvention is concerned with the improvement of .the organic metal salt-oil blend after it has been formed. v"'Ihis.. .vil-metal salt mixture can be formed in any convenient manner. The mixed acids may be co-neutralized in situ in the oil if desired. This is particularly desirable in cases in which the salts have the same metal constituent. The mixture of metal salts can also be prepared by separately preforming the salts in aqueous media and then dehydrating. They also can be formed separately in volatile solvents with removal of the solvent'before the metal salts are added to the lurbicating oil. It is important that the final composition arrived at be substam tially anhydrous. This is done by cooking the oil containing the metal salts at a temperature in the range of 250 F. to 350 F. until the water content is below 0.5 wt. percent.
A particularly preferred method of manufiacturingthe starting material used in this invention, when using lime to form the salts, is to add the lime in two portions. Commercial hydrated lime can contain up to of calcium carbonate which is not too reactive and generally causes excess alkalinity in the final product. This carbonate forms sediment in sight-glasses and in some manner imparts greater viscosity to the finished lubricant.
When all of the lime is added at one time, the acids are taken up by reaction with the hydrated lime. By employing a slight (24%) deficiency in the amount of lime first added, the excess acid, particularly the acetic acid, will then react with the calcium carbonate and remove it. The small amountof remaining excess acid is then new tralized with a second addition of hydrated lime. Thus the carbonate is kept to a very small amount in the tidal lubricant. The second addition of lime can be made after the initial saponification is complete and the mixture is hot (200-225 F.), and preferably after a determination of. free acidity has been "made. It is desirable to adjust the free alkalinity at this point because higher temperatures would volatilize the free acetic acid. Also it is desirable that the second addition of lime be willcient to make the lubricant slightly alkaline.
After being prepared, the oil so obtained containing the metal salts in an amount in the range of 20 to 50 wt. percent, is then treated according to the method of this invention.
EXAMPLE 1 With reference to the attached flow sheet, the commercial manufacture ofa fluid lubricating composition according to the method of this invention will be described. The following ingredients were used:
I The intermediate molecular weight acid was a commercially available acid having approximately the following composition:
Percent Oaprylic acid 28.0 Oapric acid. 56.0 Laurie acid. 16. 0
2 The lubricating oil was obtained by hydrotlning of a coastal distillate "and had the following inspections:
A.P.I. Gravity. 210 min. Color I 3-4 (N.P.A.) Flash0pen Cup. 440 F. min. Pour oint 15 F. max.
7,600 pounds of the mineral oil from source 1 were admitted by line 2 to a steam-jacketed 18,000 lb; capacity 'kettle' 3 equipped'withscraper blades. 1,776poundsof weight acid'from source' o via line 7 -at approximately 30 lbs. perminute. After complete'addition of the mixed acids, the product fwas mixed at top paddlespe'ed (3.4 r.p.m.) for about two hours. The mass was then heated to 320 and' held arthis temperature for two-hours to plete, the -screen -is :allowed to drain for -15 -minutes dehdyrate it (02-05% water). The phenyl alpha naphthylamine was then added, the mixture was cooled by passing cold water to the kettle jacket, and diluted with 1200 gallons of the lubricating oil. The mixture was cooled to 150 F. and formed a semi-solid grease. This grease was then pumped by line 8 through a homogenization zone 9 comprising a model G-1'25 Charlotte mill set at 0.004 inch clearance. The homogenized mixture was then transferred by line 10 to a 36,000 lb. storage tank '11. The sulfated ash and free alkali of the base at this time were: Sulfated ash, 15.82 wt. percent and free alkali as NaOH, 0.50 wt. percent.
From storage 11.the grease was passed by line 12 to a homogenization zone 13 comprising a model G-125 Charlotte mill set at 0.004 inch clearance. After this homogenization, the material was passed by line 14 to a 70,000 lbs. storage tank 15 equipped with a side entrance mixer. In this tank the homogenized material was diluted to the desired soap content, with additional lubricating oil supplied from zone 17 via line '18 as measured by a sulfated 'asli (CaSO of 5.5 to 5.8%. After addition of 6,210 additional gallons of the lubricating oil, the sulfated ash was 5.5 wt. percent, and the material had a viscosity of 1766 SSU at 100 F. and 132 SSU at 210 F.
After dilution, the mixture was passed by line 19 to a third homogenization zone 20 comprising a model Charlotte mill set at 0.004 inch clearance. The thricehomogenized material "was then transferred by line 2-1 the preferred inspections limits for the product of this 1nvention.
Table l Desired Specifications Tests This Invention Minimum Maximum Viscosity, SSU@ F-- -1, 700 1,900 1,760 .Yiscosity, SSU@210 F.- 132 Sulfuted Ash, Percent 5. 5 5.8 5. 5
Centrifuge Test, Wt. Percent Solids 4 Hours at 1,500 r m 5 2. 2 Screen Test (40 Mesh) Pass Free Alkalinity, Percent--. 0.05' 0. 30 0. 15 Water by Distillation, Percent- 0.2 0.15 4 Ball Wear Test, Scar Spot Diameter. mm. (1,800 r.p.m.10
Kg. Load-75 0., 1 hour) 0.20
I No lumps, jeily or dirt.
-when centrifuged (with-no dilution with ASTM naphtha) for four hours at 1500 r.p.m. and 120 F. in the centrifuge-test for stability, usingthe centrifuge and cone- -'shaped cer' tritu'ge tubes described in ASTM B-91-40,
Standard'Method of Test Precipitation No. of Lubricating Oils.
Tlie screen test comprises fitting a four-inch, 40.-r'nesh screen (of -any suitable material) to a Biichner tunnel. The -ift'aur-inch screen 'is weighed and placed in the funnel, then without usinga suction, one quart 'of the lubric'ant-is passed thr'oughthe screen at'a temperature of-about-75 Afterfiltering of the sample is com- 'and then is wiped-off on' the bottom andreweighed. ilhe "screen-is --examinedfor lumps, jelly, crystals and dirt.
Weights in excess of about 0.5 gram indicate the presence-:of jellyand possiblywater.
t .The free alkalinity is determined by ASTM. Meth-- odsof Analysis of Grease (D-128-47).
I. The sulfated ash test isaccording to ASTM D-874-51; Method of Test for Sulfated Residue From New Lubricating Oils.
Water content is determined by ASTM D-95-46, Method of Test for Water in Petroleum Products and Other Bituminous Materials.
The viscosities are determined according to ASTM D-44546 using Ubbelohde viscosity tubes, size No. 3.0 for the 100 F. determination and size No. 0.3 for the 210 F. determination. With one filling of the viscosity tube, four successive determinations are made, the first one-being discarded becausethe lubricant is non-Newtonian. The average of the last 'three runs is the viscosity used.
The four ball .wear test scar spot indicates the excellent anti-wear resistance of the lubricant of this in vention. Friction and wear is determined in this test by the precision-shell four ball wear tester described in a United States Steel Lubricants Testing Laboratory, National Tube Division, Report, November 1, 1952. The conditions are:
1800 r.p.m. 1 hr. duration 75 C. kg. load The term homogenization is intended to include any method of subjecting the lubricant to shearing forces. Besides the colloidal mill (Charlotte mill) identified, this milling can be carried out using the Gaulin homogenizer made by Manton-Gaulin Company, the Morehouse mill made by Morehouse Industries, or any device capable of f imparting rates of shear approaching 100,000 to 750,000 reciprocal seconds or more. The homogenization of the concentrated (20-50 wt. percent salts) metal salt composition should be carried out to an extent sufficient so that there is no particle size above 500 microns, and the average particle size is 300 microns under microscopic scanning. The second homogenization is carried out to an extent sufficient so that the material will pass the centrifuge test above described and completely pass through the 0.008 inch filter spacings. While the temperature of homogenization does not appear to be critical, it is desirably in the range of 80 to 150 F. in order to obtain best results. v
Thedeaeration step is greatly desired because a lubricant, when employed as an upper cylinder lubricant in marine diesel engines, is passed through a'lubricator (e.g., a Manzell lubricator) that acts as a displacement pump. Any air entrained in the lubricant can cause vapor lock in-the dispensing pump or lines. Prior art preparations give relatively short lub ricator lives. However, the product of thisinvention has more than tripled lubricator life.
EXAMPLE II The following data show that it is important that the final product contain at least about 4 .wt. percent of the complex metal salts. Greases were prepared in a manner similar to that described above, having various metal salt contents, and were tested according to the four-ball wear test described .above. The scar spot diameters obtained vs. the percent sulfated ash in the lubricant are given in the following Table II.
6 EXAMPLE, 3
Three lubricants'were made up according to this in vention having the composition given in Table III.
' Table 111 Formulation (Wt. Percent) Phenyl Alpha N aphthylamine 0. Acid Treated Lubricating Oil 59. Hydrofined Lubricating O1l#l Hydrofined Lubricating Oil #2 59, S
, FINISHED LUBRICANT Acid Treated Lubricating 0il Hydrofined Lubricating Oil #1 90. 98 Hydrofined Lubricating Oil #2 Table .I V
Diol D101 80 Biol 65 Acid Hydroflned Hydroflned Treated #1 #2 Viscosity F., SSU 1, 200 1, 200 750 Viscosity 210 F., SSU. 80 65 Gravity, API p 21.0 21. 5 Flash, open cup, F. min 440 410 our Pt., F 15 0 max.
The compositions were made up as follows: A steam jacketed fully scraped kettle was charged with 5980 lbs. of a lubricating oil and 1480 lbs. of lime. These were mixed to form a smooth slurry. To the slurry was added a blend of 480 lbs. of the intermediate molecular weight acid and 2000 lbs. of acetic acid at a rateof 34 lbs. per minute. This addition was done through atop opening in the kettle while .the paddles were rotating at 17 r.p.m. After addition of the acid, the temperature-rose to 205 F. Stirring was continued for 30 minutes with the paddles at 34 r.p.m. Steam was then passed into the kettle jacket and-the temperature raised to 320 F. The heating was then discontinued and cooling water was passed through the kettle jacket. During this cooling, 10,500 lbs. of additional lubricating oil were added. The phenyl alpha naphthylamine was added and the grease at a temperature of 239 F. was-left to cool overnight. The paddle and the cooling water were shut oft.
The next day the grease was passed through a Charlotte mill set at 0.004 inch clearance. After this homogenization it was stored in a 36,000 lb. storage tank at 88 F. Approximately 7000 lbs. of this intermediate cutback material was then returned through the Charlotte mill to the kettle for final dilution. The twice-homogenized intermediate cutback material was diluted to the desired ash content and then again passed through the mill. After this it was deaerated ina Cornell deaerator and filtered in a Purolator filter using a 0.015 inch mesh screen. It was then packaged. The balance of the intermediate cutback material from the storage tank was handled similarly. The yield for each of the three compositions A, B and C was approximately drums (432 lbs. each).
The trend toward the use of low-cost residual type fuels in the large slow-speed marine engine has created an important qualityproblemin the-field of marine diesel cylinder oils, The use of residual fuels in marine engines has resulted in increased liner wear from 50 to 500% above the wear experienced with distillate fuels. Because, however, of the differential price of over $1.50 per barrel, a tanker can realize a large gross annual fuel saving of around $100,000 by using bunker fuel in place of distillates.
The lubricating composition of this invention is particularly directed to this problem of lubricating marine diesel engines. This composition differs somewhat from the conventional mineral oil distillates previously used in that it is a fluid grease and resembles most greases in appearance, although it still is free-flowing.
The major function of a diesel cylinder lubricant is to reduce friction and wear of the piston rings and liner surfaces. This is done by injecting the: lubricant into each cylinder and it is, in a large measure, consumed during fuel combustion. The increased liner wear experienced with residual fuels is believed to be mainly due to corrosion which results from the high sulfur content of residual fuel and the abrasive action of the prodnets of incomplete combustion of the heavy fuel components. Residual fuels usually range in sulfur content from 2 to 4%, while distillates generally fall under 1.5%.
Composition A of Example 3 was tested in a residual fuel burningmotor ship Esso Little Rock, an 18,000 ton tanker powered by a five cylinder 75,000 H.P., two.- cycle, single-acting, opposed piston, Sun-Doxford engine. For purposes of comparison, a high quality', premium control oil was used. This was a deasphalted, phenol treated and solvent extracted residuum from a blend of parafiinic crudes having a viscosity of 85 SSU at 210 F. and a viscosity index of 101.
After approximately 5200 hours of operation, the total wear in the cylinders lubricated with the control oil was 0.1 inch. After the same period of operation on composition A, the wear was only 0.057 inch. Thus a reduction of 43% was obtained. "Other tests with the other compositions, B and C, of Example 3 have shown that as compared to distillate lubricating oils and to detergent lubricating .oils, the composition of this invention results in decreasing liner wear from anywhere from 50 to 83% or more.
Having described this invention, what is sought to be protected by Letters Patent is succinctly set forth in the following claims.
What is claimed is:
,1. in a process wherein a substantially anhydrous fluid lubricating composition is formed at a temperature in the range of 250 to 340 F. by dispersing in a mineral lubricating oil having an initial viscosity in the range of to' SSUat 210 F. and a viscosity index in the range of 40 to 100, the metal salts of acetic acid and ,of an intermediate molecular weight monocarboxylic acid having from 7 to 12 carbon atoms, the molecular ratiol of low molecular weight acid to intermediate molecular: Weight acid being in the range Iof"10:l to 25:1, .the improvement which comprises maintaining the wt. per? cent of said metal salts in said composition in the range of 20 to 50, homogenizing the composition at least twice at a temperature in the range of 80 to F. and at a shearing force in the range of 100,000 to 500,000 reciprocal seconds, diluting the composition so homogenized with further amounts 'of said'lubricating oil until 'the weight percentage of said metal salts is in the range of- 4 to 10 and then further homogenizing the diluted com? position at a shearing force in the range of 100,000 to 750,000 reciprocal seconds and a temperature in .the range of 80 to 150 F. to obtain a fluid product .ofi improved stability having a viscosity in the range of 80 to 200 SSU at 210 F.
2. The process of claim 1 wherein said metal is calcium.
3. A process which comprises forming at a temperature in the range of 250 to 340 F., a substantially anhydrous mixture of 20 to 50 wt. percent of the calcium metal salts of acetic acid and a monocarboxylic acid having from 7 to 12 carbon atoms in a liquid lubricating oil, the ratio of acetic to said monocarboxylic acid being in the range of 10:1 to 25:1, subjecting said mixture to shearing at least twice at a temperature in the range of 80 to 150 F. and at a shearing force in the range of 100,000 to 500,00 reciprocal seconds, diluting the mixture with additional lubricating oil to a metal salt content in the range of 4 to 10 wt. percent, and then further shearing the diluted mixture at .a temperature in the range of 80 to 150 F. and a shearing force it; the range of 100,000 to 750,000 reciprocal seconds to obtain an improved fluid lubricating composition.
' References Cited in the file of this patent UNITED STATES PATENTS Plauson June 12, 1923

Claims (1)

1. IN A PROCESS WHEREIN A SUBSTANTIALLY ANHYDROUS FLUID LUBRICATING COMPOSITION IS FORMED AT A TEMPERATURE IN THE RANGE OF 250 TO 340* F. BY DISPERSING IN A MINERAL LUBRICATING OIL HAVING AN INITIAL VISCOSITY IN THE RANGE OF 55 TO 100 SSU AT 210* F. AND A VISCOSITY INDEX IN THE RANGE OF 40 TO 100, THE METAL SALTS OF ACETIC ACID AND OF AND INTERMEDIATE MOLECULAR WEIGHT MONOCARBOXYLIC ACID HAVING FROM 7 TO 12 CARBON ATOMS, THE MOLECULAR RATIO OF LOW MOLECULAR WEIGHT ACID TO INTERMEDIATE MOLECULAR WEIGHT ACID BEING IN THE RANGE OF 10:1 TO 25:1, THE IMPROVEMENT WHICH COMPRISES MAINTAINING THE WT. PERCENT OF SAID METAL SALTS IN SAID COMPOSITION IN THE RANGE OF 20 TO 50, HOMOGENIZING THE COMPOSITION AT LEAST TWICE AT A TEMPERATURE IN THE RANGE OF 80 TO 150* F. AND AT A SHEARING FORCE IN THE RANGE OF 100,000 TO 500,000 RECIPROCAL SECONDS, DILUTING THE COMPOSITION SO HOMOGENIZED WITH FURTHER AMOUNTS OF SAID LUBRICATING OIL UNTIL THE WEIGHT PERCENTAGE OF SAID METAL SALTS IS IN THE RANGE OF 4 TO 10 AND THEN FURTHER HOMOGENIZING THE DILUTED COMPOSITION AT A SHEARING FORCE IN THE RANGE OF 100,000 TO 750,000 RECIPROCAL SECONDS AND A TEMPERATURE IN THE RANGE OF 80 TO 150* F. TO OBTAIN A FLUID PRODUCT OF IMPROVED STABILITY HAVING A VISCOSITY IN THE RANGE OF 80 TO 200 SSU AT 210* F.
US634450A 1957-01-16 1957-01-16 Process of making an improved carboxylic acid salt complex thickened lubricant Expired - Lifetime US2973321A (en)

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NL97276D NL97276C (en) 1957-01-16
NL257238D NL257238A (en) 1957-01-16
NL109104D NL109104C (en) 1957-01-16
NL205854D NL205854A (en) 1957-01-16
BE546615D BE546615A (en) 1957-01-16
NL224101D NL224101A (en) 1957-01-16
GB8289/56A GB778651A (en) 1957-01-16 1956-03-16 Metal salts of carboxylic acids and compositions containing them
DEE12146A DE1053124B (en) 1957-01-16 1956-03-24 Additives and thickeners for lubricants based on mineral or synthetic lubricating oils
FR1152175D FR1152175A (en) 1957-01-16 1956-03-27 Metal salt compositions
US634450A US2973321A (en) 1957-01-16 1957-01-16 Process of making an improved carboxylic acid salt complex thickened lubricant
GB434/58A GB824526A (en) 1957-01-16 1958-01-06 Process of making an improved carboxylic acid salt complex thickened lubricant
DEE15228A DE1087736B (en) 1957-01-16 1958-01-15 Process for the production of lubricating oils with a content of metal salt mixtures or complexes
FR755962A FR73068E (en) 1957-01-16 1958-01-15 Metal salt compositions
GB34433/60A GB913579A (en) 1957-01-16 1960-10-07 Process for making an improved lubricant containing salts of carboxylic acids
FR842411A FR78613E (en) 1957-01-16 1960-10-27 Metal salt compositions

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US3068173A (en) * 1959-08-24 1962-12-11 Texaco Inc Process for preparing complex calcium salt-calcium soap grease
US3068174A (en) * 1959-08-24 1962-12-11 Texaco Inc Process for preparing complex calcium salt-calcium soap grease
US3068175A (en) * 1959-08-24 1962-12-11 Texaco Inc Process for preparing complex calcium salt-calcium soap grease
US3152079A (en) * 1961-07-03 1964-10-06 Exxon Research Engineering Co Mixed salt lubricants containing a controlled amount of water
US3155619A (en) * 1962-02-12 1964-11-03 Sinclair Research Inc Complex lubricant
WO2010003918A1 (en) * 2008-07-07 2010-01-14 Shell Internationale Research Maatschappij B.V. Grease composition
WO2010003920A1 (en) * 2008-07-07 2010-01-14 Shell Internationale Research Maatschappij B.V. Grease composition
CN109503358A (en) * 2019-01-07 2019-03-22 宁波赜军医药科技有限公司 A kind of preparation method of isooctyl acid copper

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US2930757A (en) * 1957-10-16 1960-03-29 Exxon Research Engineering Co Lubricating compositions containing salts of monocarboxylic acids and free alkalinity
US3000824A (en) * 1957-11-13 1961-09-19 Exxon Research Engineering Co Lubricating oil composition
US3033787A (en) * 1959-08-11 1962-05-08 Exxon Research Engineering Co Mixed salt lubricant compositions having improved base oils
NL258842A (en) * 1959-12-11
US3198734A (en) * 1961-06-28 1965-08-03 Exxon Research Engineering Co Lubricants comprising polyphenyl ethers and mixed metal salts of fatty acids
AT238863B (en) * 1963-07-31 1965-03-10 Oemv Ag Lubricating oil
NL137462C (en) * 1967-04-27
GB8716159D0 (en) * 1987-07-09 1987-08-12 Shell Int Research Basic salt

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US1458542A (en) * 1921-01-13 1923-06-12 Plauson Hermann Process for the manufacture of dispersoids
US2412680A (en) * 1943-08-03 1946-12-17 Edwin G Eppenbach Metering mill
US2704363A (en) * 1954-06-14 1955-03-15 Socony Vacuum Oil Co Inc Grease manufacture
GB742517A (en) * 1952-12-05 1955-12-30 Bataafsche Petroleum Process for the preparation of lubricating greases
US2734030A (en) * 1956-02-07 Mixed soap-complex grease compositions
US2735815A (en) * 1956-02-21 Preparation of soap-salt complexes
US2739127A (en) * 1952-07-02 1956-03-20 Exxon Research Engineering Co Lubricating grease containing organic carbonates
GB749729A (en) * 1952-12-05 1956-05-30 Bataafsche Petroleum Process for the preparation of lubricating greases
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US2735815A (en) * 1956-02-21 Preparation of soap-salt complexes
US1458542A (en) * 1921-01-13 1923-06-12 Plauson Hermann Process for the manufacture of dispersoids
US2412680A (en) * 1943-08-03 1946-12-17 Edwin G Eppenbach Metering mill
US2758973A (en) * 1952-05-29 1956-08-14 Exxon Research Engineering Co Process for preparing lubricating grease compositions
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GB742517A (en) * 1952-12-05 1955-12-30 Bataafsche Petroleum Process for the preparation of lubricating greases
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Publication number Priority date Publication date Assignee Title
US3068173A (en) * 1959-08-24 1962-12-11 Texaco Inc Process for preparing complex calcium salt-calcium soap grease
US3068174A (en) * 1959-08-24 1962-12-11 Texaco Inc Process for preparing complex calcium salt-calcium soap grease
US3068175A (en) * 1959-08-24 1962-12-11 Texaco Inc Process for preparing complex calcium salt-calcium soap grease
US3152079A (en) * 1961-07-03 1964-10-06 Exxon Research Engineering Co Mixed salt lubricants containing a controlled amount of water
US3155619A (en) * 1962-02-12 1964-11-03 Sinclair Research Inc Complex lubricant
WO2010003918A1 (en) * 2008-07-07 2010-01-14 Shell Internationale Research Maatschappij B.V. Grease composition
WO2010003920A1 (en) * 2008-07-07 2010-01-14 Shell Internationale Research Maatschappij B.V. Grease composition
US20110136709A1 (en) * 2008-07-07 2011-06-09 Keiji Tanaka Grease composition
US20110160105A1 (en) * 2008-07-07 2011-06-30 Keiji Tanaka Grease composition
CN109503358A (en) * 2019-01-07 2019-03-22 宁波赜军医药科技有限公司 A kind of preparation method of isooctyl acid copper

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GB913579A (en) 1962-12-19
FR73068E (en) 1960-09-22
FR1152175A (en) 1958-02-12
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NL205854A (en)
DE1053124B (en) 1959-03-19
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NL97276C (en)
FR78613E (en) 1962-08-17
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GB778651A (en) 1957-07-10
BE546615A (en)

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